Oil & Gas Pipeline

ITW Welding

W E L D I N G & H e a ting S O L U T I O N S
 Meeting the Challenges of High-Strength Pipeline Integrity

Our world is growing Partnering with Miller and Hobart Brothers gives you
and changing. An decades of global experience — a history that includes
increasingly urbanized pipeline construction in some of the harshest and most
population — poised to
remote environments on Earth.
reach 9 billion by 2050
— is driving demand for High-strength materials — like API 5L Grades X70 to X100 — are designed to expedite
pipe lay time, reduce costs and simplify transport. Whether it’s building across desert
new energy sources terrain, up the side of a mountain or through the frigid tundra, high-strength steel offers
and innovation in energy- a history of quality, safety and proven results.
based construction and • Excellent strength properties provide greater carrying capacity, along with the ability
to withstand increased pressure tolerances.
infrastructure. We can
help you meet those • The ability to withstand temperature extremes, thermal expansion and contraction,
frost and other environmental loadings for global construction.
demands.
• Thinner wall thicknesses that require less time to weld, less filler metals to
complete passes and lower costs for transporting materials to jobsites.
• Lower cost per foot compared to lower-strength steels.
As high-strength steels become more prevalent in the global pipeline market, matching
the proper filler metals, welding processes and heat treatment to the pipe can ensure
the highest level of integrity, quality and productivity in pipeline construction.

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 Oil & Gas Pipeline
Addressing the challenges of welding high-strength steels
High-strength steels require special attention to maintain their integrity throughout the
welding process. Key to achieving that goal is minimizing the opportunity for hydrogen-
induced cracking.
High-strength steels also require:
• Filler metals to match the various alloying strategies for high-strength steels and
meet the necessary impact properties.
• New welding systems with innovative processes to optimize the weld performance
and durable designs to meet the rugged requirements of pipeline construction.
• Tightly-controlled pre-heat temperatures of the root pass and interpass
temperatures for the fill and cap passes.
Together, Miller and Hobart Brothers have developed proven innovative solutions to
address these needs. From welding equipment and filler metals tailored to high-
strength steels, to induction heating designed to control pre-heating, interpass
temperatures and post-weld stress relief, our technologies work together to reduce the
risk of hydrogen-induced cracking and ensure you achieve the highest quality welds.
Ask our global network of welding professionals to help you place the
most reliable welding and heating systems for this demanding application
in the hands of your team.

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 Getting to the Root of Welding
High-Strength Steels
Maintaining the quality and safety of the pipeline is absolutely critical. Our
metal-cored wires and the Regulated Metal Deposition (RMD®) process for root
passes, combined with induction heating, ensure the consistency and quality
you need.
Before you even strike an arc, induction heating can help drive out moisture and
minimize hydrogen in the weld joint. The process minimizes the opportunity for
cracking by slowing the cooling rate, allowing hydrogen to diffuse, and offsetting
thermal shock.
Adding to those pre-weld advantages, metal-cored wire and the RMD process
further improve the integrity of the root pass by providing consistent and reliable
root reinforcement. The technologies also provide: Induction heating process
• An exceptionally stable arc and calm weld puddle — both of which help
improve weld quality and consistency, and reduce the opportunity for defects
like lack of fusion.
• Greater tolerance of code-allowable high-low misalignment.
• A fast-freezing puddle that can bridge gaps up to 5 mm (3/16 inch) and
provide a root pass with a throat between 3 to 5 mm (1/8 to 3/16 inch) thick
(for .045-inch wire).
• A weld bead with little or no spatter that typically does not require interpass
grinding or cleaning due to the lack of slag in the process.
E6010 SMAW electrode root pass
• A consistent arc length, even at varying wire stick-out, to simplify training.
• Greater deposition efficiency compared to cellulosic Stick electrodes.

Metal-cored wire/RMD root pass

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 Oil & Gas Pipeline
Hobart Brothers Metal-Cored Wires
Products AWS Class Shielding Gas Tensile Yield CVN @ Temp Typical Diffusible Recommended Pipe Grade
psi (MPa) psi (MPa) ft-lb (Joules) Hydrogen*
(ml/100g)
Metalloy® E70C-6M H4 75–95% Argon (Ar)/Balance 87000 77000 53 (72) 1.9 Root pass up to X70 Pipe
76 Carbon Dioxide (CO2) (600) (530) @ -20°F (-30°C)
Metalloy E70C-6M H4 75–90% Argon (Ar)/Balance 84000 74000 88 (120) 3.3 Root pass up to X70
71SG Carbon Dioxide (CO2) (579) (510) @ -40°F (-40°C) Pipe & sour gas pipeline
applications
Metalloy E80C-Ni1 H8 75–95% Argon (Ar)/Balance 91000 83000 56 (76) 2.3 Root pass up to X80 Pipe
80N1 Carbon Dioxide (CO2) (627) (527) @ -50°F (-45°C)
Metalloy E90C-K3 H4 75–95% Argon (Ar)/Balance 102000 94000 47 (64) 2.3 Root pass up to X80 Pipe
90 Carbon Dioxide (CO2) (703) (648) @ -60°F (-51°C)
Metalloy E110C-K4 75–95% Argon (Ar)/Balance 118000 105000 43 (58) 3.1 Root pass up to X100 Pipe
110 Carbon Dioxide (CO2) (810) (725) @ -60°F (-51°C)
Completed welds provide excellent impact properties — as low as -40 degrees F/C — to compensate for extreme temperatures. Weld deposits
feature as low as 4 ml of diffusible hydrogen per 100 g of weldment compared to up to 16 ml per 100 g with cellulosic Stick electrodes.
*Typical diffusible hydrogen data with shielding gas 75-80% Argon (Ar)/Balance Carbon Dioxide (CO2)

Deposition Efficiency for Metal-Cored Wire

Using RMD vs. SMAW E6010
100%

90%

80%
Efficiency

70%

60%

50%

40%
(100) (125) (150) (175) (200) (225)
95 115 130 145 165 175 RMD root face
Wire Feed Speed (IPM) & Amps for SMAW
Deposition Efficiency (%) Deposition Efficiency (%) SMAW

The increased deposition efficiency of metal-cored wire vs. E6010 cellulosic Stick
electrode ensures that the majority of metal-cored wire is going into the puddle
as finished weld vs. the Stick electrode where a large percentage is being lost in
spatter, slag and stub loss.

Typical Diffusible Hydrogen Levels of

SMAW EXX10 vs. Metal-Cored & FCAW-S
44.0
40.0
36.0
32.0
28.0
Diffusible 24.0
Hydrogen 20.0 RMD root side
(ml/100g) 16.0
12.0
8.0
4.0
0.0
1 2 3 4
Cellulosic EXX10 31.0 39.6 28.2 40.3
Metalloy Metal-Cored 2.5 3.3 6.4 2.3
Fabshield FCAW-S Flux-Cored 6.4 5.5 7.3 –

The low hydrogen solution of metal-cored and self-shielded flux-cored wire will
deposit less hydrogen into the weld puddle, decreasing the chance for hydrogen-
induced cracking.
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 A New Pass at Fill and Cap
The alloy in high-strength steels, combined with the high hydrogen levels that
cellulosic Stick electrodes produce, makes welds more prone to hydrogen-
induced cracking. Shifting from Stick welding (SMAW) to Self-Shielded Flux-Cored
welding (FCAW-S) for fill and cap passes reduces hydrogen content, helps ensure
weld integrity and offers substantial benefits to the welding process:
• Easily welds API 5L Grades X70 up to X100: qualified and currently used in
high-strength steel applications around the globe.
• Lower hydrogen content to reduce cracking: Self-shielded flux-cored wires
feature less than 8 ml of diffusible hydrogen per 100 g of weldment (compared
to greater than 16 ml per 100 g for cellulosic Stick electrodes).
• Excellent impact properties: To combat the environmental extremes high-
strength pipelines are subjected to, self-shielded flux-cored wires feature
excellent Charpy V-Notch (CVN) impact values at temperatures as low as
-40 degrees Fahrenheit/Celsius. Final cap pass with Hobart®
Fabshield® flux-cored wire
• Increases in speed and deposition efficiency: Self-Shielded
Flux-Cored welding provides faster travel speeds — more pounds per hour —
and offers greater filler metal deposition efficiency compared to welding with
cellulosic Stick electrodes. In short, your operators will use less filler metal to
do the same job and do it in less time.
• Better arc control: Excellent arc quality and dual schedule capabilities give
the welding operator better control over the welding arc, even in difficult
positions toward the bottom of the pipe (4 to 6 o’clock).
• Eliminates shielding gas: Process eliminates the need for a shielding gas,
reducing the cost, transportation and storage of gas bottles.

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 Oil & Gas Pipeline
Hobart Brothers Self-Shielded Flux-Cored Wires
Products AWS Class Shielding Tensile Yield CVN @ Temp Typical Diffusible Recommended Pipe
Gas psi (MPa) psi (MPa) ft-lb (Joules) Hydrogen Grade
(ml/100g)
Fabshield® 81N1 E71T8-Ni1 J H8 None 75000 65000 206 (280) @ -40°F (-40°C) 6.4 Fill & Cap up to
(517) (448) X65 Pipe
Fabshield 81N1+ E71T8-Ni1 J H8 None 82000 71000 106 (128) @ -20°F (-29°C) 5.5 Fill & Cap up to
(565) (490) 71 (96) @ -40°F (-40°C) X70 Pipe
Fabshield X80 E81T8-Ni2 J H8 None 94000 84000 83 (113) @ -20°F (-29°C) 5.2 Fill & Cap up to
(649) (578) 70 (95) @ -40°F (-40°C) X80 Pipe

Hobart Brothers Gas-Shielded Flux-Cored Wires

Products AWS Class Shielding Tensile Yield CVN @ Temp Typical Diffusible Recommended Pipe
Gas psi (MPa) psi (MPa) ft-lb (Joules) Hydrogen Grade
(ml/100g)
Formula XL®-550 E71T-1C / 100% Carbon Dioxide (CO2) 85000 77000 75 (102) @ 3.3 Fill & Cap up to
E71T-12CJ H4 (586) (531) -40°F (-40°C) X65 Pipe
FabCO® 712M E71T-1MJ H4 / 75-80% Argon (Ar)/Balance 79000 70000 100 (135) @ 3.4 Fill & Cap up to
E71T-9MJ H4 / Carbon Dioxide (CO2) (544) (482) -40°F (-40°C) X65 Pipe
E71T-12J H4
Tri-Mark® TM-101 E101T1-GM 75% Argon (Ar)/25% Carbon 110000 102000 52 (71) @ 5.1 Fill & Cap up to
Dioxide (CO2) (758) (703) -40°F (-40°C) X80 Pipe
FabCO XTREME® E121T5-GC H4 100% Carbon Dioxide (CO2) 125600 110700 75 (101) @ 3.4 Fill & Cap up to
120 (866) (763) -76°F (-60°C) X100 Pipe

Other customized formulations for specific applications available upon request.

Deposition Rate and Efficiency for Self-Shield

FCAW-S vs. SMAW EXX10 Cellulosic Electrodes
75% 6.0
Deposition Rate (lb/hr)

70% 5.0
65%
4.0
Efficiency

60%
3.0
55%
2.0
50%

45% 1.0

40% 0.0 Induction heating helps maintain critical

(65) (75) (85) (90) (100) (125)
95 115 130 145 165 175 interpass temperature control, removing
moisture and hydrogen between passes,
Wire Feed Speed (IPM) & Amps for SMAW further reducing cracking and improving
weld quality.
Deposition Efficiency of Deposition Efficiency of
SMAW EXX10 Fabshield FCAW-S
Deposition Rate of Deposition Rate of
SMAW EXX10 Fabshield FCAW-S

This graph illustrates the increase in deposition rate and more consistent
deposition efficiency when using a self-shielded flux-cored wire vs. an EXX10
cellulosic Stick electrode.

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 Welding Solutions

Each component of the welding process — filler metal and equipment — can affect the amount of
hydrogen in the weld, but combining their attributes into one optimized system ensures the best
results. These systems from Miller and Hobart Brothers are easy to operate and are designed
to withstand the harshest environments found in pipeline construction — tested above and beyond
the highest industry standards to ensure durability and performance.

PipePro XC
Power Source PipePro XC
PipePro®XC RMD Feeder
Feeder

Bernard PipeWorx Gun

Bernard PipePro
Dura-Flux Gun

Miller®PipePro®XC welding system

The PipePro XC welding system from Miller is optimized for both the RMD®process with metal-cored
wire on root passes and the Self-Shielded Flux-Cored process with flux-cored wires for fill and cap
passes. These systems offer easy operation through intuitive design and interface, are fast to set
up in the field and ensure optimal performance with rugged design and construction. The PipePro XC
system is also compact for optimal transport and space considerations on-site.
• Multiprocess system is optimized for the welding processes — RMD and Self-Shielded Flux-Cored
— and best suited to reduce hydrogen in the weld.
• Excellent arc performance and greater tolerance for varying welder techniques support consistent
weld quality.
• Intuitive design, controls and interface make it easy to set up and train welders — ensures welders
get up to speed faster and are more productive.
• Durable construction withstands extreme conditions related to temperature, moisture, dust,
vibration and shock.
• Lightweight, small footprint facilitates tractor mounting and is portable for tie-ins and repairs.
• Upgradeable software, custom programs and optional features available through memory card.

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 Big Blue® 350 PipePro® with SuitCase® X-TREME Big Blue 700 Duo Pro®
HD and Bernard Dura-Flux Gun (Engine Driven)

Oil & Gas Pipeline

Miller®Big Blue®engine-driven welder/generators
The Big Blue 350 PipePro and the Big Blue 700 Duo Pro diesel engine-driven welder/generators,
matched with SuitCase X-TREME HD wire feeders, are optimized for pipeline and specifically for Self-
Shielded Flux-Cored welding on fill and cap passes. Both machines are built to withstand temperature
and environmental extremes for optimal performance regardless of conditions. The Big Blue 700 also
represents the industry’s only dual operator welding system for transmission pipeline construction.
Big Blue 350 PipePro
• Excellent arc performance designed specifically for self-shielded flux-cored wires in pipeline
applications promotes weld quality.
• Easy-to-use operator interface simplifies training and equipment setup.
• Built and tested in high and low environmental extremes — as well as against moisture, dust,
vibration and shock — ensuring reliability and performance even in the toughest environments.
• Greater fuel efficiency to reduce fuel transportation costs and labor; lower emissions for reduced
carbon footprint.
Big Blue 700 Duo Pro
• Features two welding arcs that match the quality and reliability of the Big Blue 350 PipePro.
• Increases productivity by allowing two welders to work from the same machine simultaneously.
• Uses 35 percent less fuel and offers a lower total cost of ownership than two comparable engine-
driven units, saving resources and costs.
• Costs less to transport to the jobsite than two individual engine-driven units and takes up a
considerably smaller footprint to save space.

Hobart Brothers metal-cored and flux-cored wires

Hobart Brothers manufactures metal-cored and flux-cored wires designed
to drive hydrogen out of the weld, ensure pipeline integrity with excellent
strength and impact properties in harsh environments, and work
seamlessly with Miller welding power sources and feeding technologies.
Wires optimized for each process include:
• Metal-cored and RMD: Hobart®Metalloy®76, Metalloy 71SG, Metalloy
80N1, Metalloy 90 and Metalloy 110
• Self-shielded flux-cored wires: Fabshield®81N1, 81N1+ and X80 Hobart Brothers
tubular wires
• Gas-shielded flux-cored wires: Hobart Formula XL®-550, FabCO®712M,
FabCO XTREME®120 and Tri-Mark®TM-101
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 Superior Pre-Heat and
Post-Weld Heat with Induction Heating
Pre- and post-weld heat treatment is a critical requirement in eliminating
hydrogen-induced cracking in high-strength steels. Whether on the mainline, on
tie-ins or at compressor/pumping stations, induction heating provides superior
preheating and stress relief that is more effective, faster, more versatile and
extremely safe compared to other methods. The induction heating process:
• Drives and keeps moisture out of the weld to
prevent hydrogen-induced cracking. This is a particular
improvement over heating with a torch/rosebud, which
actually introduces water vapor into the weld joint.
• Heats uniformly to prevent localized hot and cold
spots that can affect weld integrity and offers real-time
thermocouple feedback, along with tighter control over
welding interpass temperatures to ensure heating
consistency.
• Reduces the potential for damage and the associated
repair time to surrounding parts/components/coatings
by limiting heat to the targeted area.
• Improves safety by eliminating open flames and exposed The ProHeat 35 induction heating system
heating elements. from Miller diffuses moisture out of the weld,
further reducing hydrogen in the weld and
• Improves safety in confined spaces, as induction heating does not burn
the chance of hydrogen-induced cracking.
oxygen like heating with a torch or rosebud, which can lead to insufficient
breathable air for the worker.
• Provides faster time-to-temperature than other heating methods, increasing
productivity.
• Allows equipment and accessories to be carried on the same tractor or sled
as the welding power sources for improved portability and accessibility.
• Eliminates heating gas purchase, storage and transport — lowering costs
over time and improving site logistics.
• Optional digital recorder stores temperature data for quantifiable verification
of critical preheating and stress-relieving temperatures.

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 Oil & Gas Pipeline
Our ITW Partners

Miller and Hobart Brothers are just two of the ITW Welding companies who have a well-established history
of providing proven, innovative products to the pipeline industry. ITW has a global, market-leading portfolio of
best-in-class brands that serve the industry with reliable and responsive technical expertise. Our other oil and
gas pipeline partners include:

Pipe Welding Technology (PWT) (www.pwtsrl.com) is a manufacturer and supplier of

advanced equipment and tools for automatic welding in outdoor applications. This includes
advanced mechanical, electronic and arc control technology for the pipeline industry. PWT’s
vast field experience and consultative approach ensures customers have the most suitable
welding techniques, systems and training available for every job.

E.H. Wachs®(www.ehwachs.com) is a leading manufacturer of portable pipe machining tools,

valve exercisers and related equipment used for on-site cutting, squaring, beveling and facing
pipe of all sizes and thicknesses. Its “cold cutting” machine tools are designed to eliminate
the hazards associated with thermal cutting and improve the overall safety of pipeline
operators. The company has been an industry leader in pipeline maintenance since 1949.

ITW Insulation Systems (www.itwinsulation.com) is an established leader in the manufacture

of products used in mechanical insulation systems for pipes, tanks and other equipment.
ITW Insulation Systems provides high-performance mechanical insulation, vapor retarder film
and metal jacketing products designed to meet specifications for a wide range of industrial
and commercial applications.

Tempil®(www.tempil.com), a leader in the development of precision temperature indication

technologies, including indicating sticks, electronic surface thermometers and infrared
thermometers, for over 75 years. These “visual” product solutions check critical
temperatures in the welding processes and ensure the performance of completed pipelines.
Tempil stays at the forefront of the industry through constant research and product
development that address the direct needs of its customers.

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Countless capabilities.
Trusted advice.
Integrated solutions.
As your global partner in pipeline construction, For all your global pipeline welding solution needs contact:
Welding Industries of Australia
we pledge to support your success with our unique 61-387-95-8241
info@welding.com.au
multi-discipline knowledge and in-depth pipeline Beijing Miller
86-10-8739-7080
admin@millerchina.com
construction experience. Our goal is to ensure you ITW Welding SAS—France
33-1-6004-1166
miller@itw-welding.fr
achieve consistent weld integrity, no matter how
ITW Welding—India
91-79-3315-4001
challenging the environment — and no matter rajesh.mandhyan@itwindia.com
ITW Welding Products—Italy
where you are in the world. 39-02-98-29-01
miller@itw-welding.it
Welding Products Group—
Latin America
786-235-8143
nafons@millerwelds.com
ITW Welding Products Group—Mexico
52-55-5366-7370
ventas@itwwelding.com.mx
ITW Welding
MillerWelds.com
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ITW Welding—Middle East (FZE)
971-4-299-6621
contact@itw-me.ae
ITW Welding Products BV—
Netherlands/UK
31-186-641-444
info@itw-welding.nl
Weldwell New Zealand
64-6834-1600
admin@weldwell.co.nz
North American Pipeline
937-332-5385
mike.macgillivray@itwwelding.com
ITW Welding Products—Russia
7-495-232-53-27
yury.golovanchikov@itw-welding.ru
ITW Welding Singapore Pte. Ltd.
65-6552-1223
vmarta@millerwelds.com
ITW Welding Products—Spain
34-96-393-5398
vcubero@itw-welding.es
HobartBrothers.com